Split-torque gear box

ABSTRACT

A split torque gearbox system provides a multiple path, three stage power gear train that transmits torque from a high-speed engine to a low speed output shaft, while providing equal gear load distribution with a floating pinion in the second stage of reduction. The number of the split modules in the gearbox depends on gearbox configuration, number of high speed input shafts, and transmitted power. The split modules are located around a last stage output gear that combines power from each module and transmits the power to an output such as a main rotor system.

BACKGROUND OF THE INVENTION

The present invention relates to a split torque gearbox, and more particularly to a rotary wing aircraft gearbox system.

A gearbox system of a rotorcraft or propeller-driven aircraft transfers power from a turbine engine to the rotor or propeller of the rotorcraft or aircraft. A typical system may direct power from several turbine engines to a single rotor or propeller. Since the rotational velocity of the rotor or propeller is significantly lower than the rotational velocity of the turbine engines, the turbine engine rotational velocity must be reduced by the gearbox system. In reducing the rotational velocity of the turbine engine output, torque is increased through a series of intermediate gear stages and shafts, before the final output drive is provided to the rotor. Relatively large gears are required near the final output drive to handle the high torque supplied to the rotors.

One prior art system includes a number of gears arranged for providing split-torque paths. The torque normally carried by a single drive train path is carried by two drive train paths to thereby split the torque of the original drive train path. The combined weight of these two split-torque paths is significantly less than the weight of the original single drive train path. While this prior art split torque system has managed to increase the horsepower-to-weight ratio in some situations, especially where total horsepower involved is substantial and where multiple input drive paths from different engines are present, this conventional approach still requires a relatively large weight and a relatively large volume.

Moreover, many conventional and split-torque gearbox systems are somewhat heavy and voluminous due to unequal load sharing. Unequal load sharing typically results when the transmission may not consistently split the load. This requires each gear to be sized to a dimension larger than optimal so as to assure adequate load capability even when the load is not consistently split. Furthermore, typical gearbox systems provide a single load path in which significant damage to a single gear may result in the disablement of the entire system.

Accordingly, it is desirable to provide a split torque gearbox system that is relatively uncomplicated and inexpensive to manufacture, has a reduced weight, and packaging size, assures an even split of loads, and generates independent redundant load paths.

SUMMARY OF THE INVENTION

The split torque gearbox system according to the present invention provides a multiple path, three stages power gear train module that transmits torque from a high-speed engine to a low speed output shaft, providing equal gear load distribution due to floating pinion in the second stage of reduction.

Each split torque module is driven by a high-speed input shaft. The input shaft engages a face gear which provides the first stage The face gear, through a pinion shaft, drives a floating pinion. The pinion shaft provides a flexibility which defines a floating pinion displacement envelope. At the second stage, the floating pinion engages a first spur gear and a second spur gear. The floating pinion axis of rotation is displaceable within the displacement envelope such that the load of the floating pinion is effectively split between the first spur gear and the second spur gear. The first spur gear and the second spur gear thereby receive an equal amount of torque.

A first double helical gear is driven by the first spur gear about the first spur gear axis of rotation. A second double helical gear is driven by the second spur gear about the second spur gear axis of rotation. The first and second double helical gears are axially displaceable such that engagement between the first and second double helical gears and an output gear provides effective load sharing and center seeking capability. That is, in order to provide a load sharing the double helical pinion moves vertically to provide instant contact with upper and lower helical mesh of the double helical output gear. As the two spur gears are engaged with the floating pinion, which is movable within floating pinion displacement envelope, the center of the pinion will travel to balance the loads coming from both gear meshes.

The number of the split modules in the gearbox depends on vehicle configuration, number of engines and transmitted power. The modules are located around the last stage output gear that combines power from each one and transmits it to the main rotor.

The present invention therefore provides a split torque gearbox system that is relatively uncomplicated and inexpensive to manufacture, has a reduced weight, and packaging size, assures an even split of loads, and generates independent redundant load paths.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:

FIG. 1 is a general schematic view of an exemplary rotary wing aircraft embodiment for use with the a split torque gearbox system present invention;

FIG. 2 is a perspective view of a split torque gearbox module according to the present invention;

FIG. 3 is an expanded perspective view of a floating pinion gear designed according to the present invention;

FIG. 4 is a schematic top view of a floating pinion gear;

FIG. 5 is a perspective view of a multiple of split torque gearbox modules according to the present invention;

FIG. 6A is a perspective view of a split torque gearbox system according to the present invention;

FIG. 6B is a general schematic view of the split torque gearbox system of FIG. 6A;

FIG. 7 is a schematic side view of a split torque gearbox system according to the present invention;

FIG. 8 is a perspective view of another split torque gearbox system according to the present invention; and

FIG. 9 is a perspective view of another split torque gearbox system according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a general schematic view of a split torque gearbox system 10. In the case of a rotary wing aircraft transmission, the system 10 is interposed between one or more gas turbine engines (illustrated schematically at 12) and a rotor assembly (illustrated schematically at 14).

The split torque gearbox system 10 generally includes three stages S1, S2 and S3. Each stage includes a plurality of links L1-Ln. Each link represents gears which splits the torque from the engine 12. Each link is preferably structurally designed based on the transmitted portion of the total load for that link. That is, because of the equality of the load split, each link need not be over designed for a greater capacity as was heretofore required to assure transmission of an unequally split load.

Referring to FIG. 2, a split torque module 16 of the gearbox system 10 is illustrated. Each split torque module 16 generally includes the three stages S1, S2 and S3. The split torque module 16 may be combined in various multiples so as to reduce the size of each module while providing a desired reduction in the rotational input velocity of one or more engine 12 inputs and a desired torque output to drive one or more rotor systems 14.

The split torque module 16 is driven by a high speed input shaft 18 preferably driven by the gas turbine engine 12. The input shaft 18 engages a face gear 20 at a first face gear mesh 22. The face gear 20 rotates about a face gear axis of rotation F. The face gear mesh 22 provides the first stage and is generally disk shaped and perpendicular to the axis of rotation F. It should be understood that other gear teeth arrangements such as a spiral bevel gear arrangement will also benefit from the present invention.

The face gear 20, through a pinion shaft 26, drives a floating pinion 24. The pinion shaft 26 defines a pinion gear axis of rotation P which is displaceable off the face gear axis of rotation F (schematically illustrated in FIG. 3). Preferably, the pinion shaft 26 provides a flexibility which defines a pinion gear displacement envelope De (FIG. 3). It should be understood that other non-rigid or unsupported mounting arrangements which provide displacement envelope De will also benefit from the present invention.

At the second stage S2, the floating pinion 24 engages a first spur gear 28 and a second spur gear 30. The first spur gear 28 rotates about a first spur fear axis of rotation R1 and the second spur gear 30 rotates about a second spur gear axis of rotation R2. The first spur gear axis of rotation R1, the second spur gear axis of rotation R2 and the pinion gear axis of rotation P are located along a common line L (FIG. 4). The pinion gear axis of rotation P, however, is displaceable off the face gear axis of rotation F and off the common line (FIG. 4) such that the load of the floating pinion 24 is effectively split between the first spur gear 28 and the second spur gear 30. The first spur gear 28 and the second spur gear 30 thereby receive an equal amount of torque.

A first double helical gear 32 is driven by the first spur gear 28 about the first spur gear axis of rotation R1. Preferably, the first double helical gear 32 is connected to the first spur gear 28 through a first spur gear shaft 34 which rotates about the first spur gear axis of rotation R1. The first spur gear shaft 34 is supported upon roller bearings 36 or the like.

A second double helical gear 38 is driven by the second spur gear 30 about the second spur gear axis of rotation R2. Preferably, the second double helical gear 38 is connected to the second spur gear 30 through a second spur gear shaft 40 which rotates about the second spur gear axis of rotation R2. The second spur gear shaft 40 is supported upon roller bearings 42 or the like.

Preferably, the first and second double helical gear 32, 38 are axially displaceable (schematically illustrated by arrows A) along shafts 34, 40 (FIG. 3) respectively. At a third stage S3, the first and second double helical gear 32, 38 engage an output gear 44 which includes a double helical mesh for meshing engagement with the first and second double helical gear 32, 38. The first and second double helical gear 32, 38 drive the output gear 44 about an output axis of rotation O.

In order to provide a load sharing the double helical gears 32, 38 are free to move axially to provide instant contact with upper and lower helical mesh 44 a, 44 b of the output gear 44. Since the two spur gears 28, 30 are engaged with the floating pinion 24 it will travel to balance the loads coming from both gear meshes. For this reason, the gears 28, 30 of the second stage and the pinion 24 are located on the common line L.

As the first and second double helical gear 32, 38 are axially displaceable (arrows A), engagement between the first and second double helical gear 32, 38 and the output gear 44 provides effective load sharing and center seeking. That is, the meshing engagement of the double helical mesh will compensate for unequal load distribution by axial movement of the first and second double helical gear 32, 38 relative the output gear 44. Moreover, after movement of the first and second double helical gear 32, 38 out of axial central alignment with the output gear 44, the meshing engagement of the double helical mesh will drive the first and second double helical gear 32, 38 back toward the axial center.

The output gear 44 drives the rotor assembly 14 about output axis of rotation O. It should be understood that systems other than a rotor system will also benefit from the present invention. The inventive gear arrangement of the present invention is not limited to just prop rotor applications.

Referring to FIG. 5, a multiple of input shaft gears 46 a, 46 b are arranged along the input shaft 22 to engage a multiple of face gears 20 a, 20 b which drive a respective module 16 a, 16 b as described above. It should be understood that numerous combinations of modules will benefit from the present invention

Referring to FIG. 6A, a multiple of engines 12 a, 12 b each drive a respective input shaft 22 a, 22 b such that a multiple of modules 16A1, 16B1, 16A₃, 16B₂ drive a common output gear 44. A relatively flat gear split torque gearbox system 10 is thereby provided which provides multiple load paths in which the failure of a single module will not fail the entire system 10″ (FIG. 6B).

Referring to FIG. 7, the input shaft 22 is angled such that an input shaft axis of rotation 1 is non-perpendicular to the pinion shaft axis of rotation P to provide for stacking of the modules 16. The angled an input shaft axis of rotation I provides for engagement of each input shaft gear 46A, 46B with a respective face gear 20A, 20B. That is, the angle of the input shaft axis of rotation I provides a mesh between input shaft gear 46A and face gear 20A while providing a clearance between input shaft gear and face gear 20b. Likewise, the angle of the input shaft axis of rotation I provides a mesh between input shaft gear 46B and face gear 20B while providing a clearance between input shaft gear 46B and face gear 20A.

Preferably, the pinion shaft axis of rotation Pa, Pb of modules 16 a, 16 b are common. That is, modules 16 a, 16 b are stacked along a common pinion axis P. A multiple of stacked modules are readily achievable which drive a multiple of output gears 44 a, 44 b to drive a common rotor assembly 14 (FIG. 8). Double the modules of FIG. 6 (Eight modules) thereby drive a single rotor shaft assembly 14 with two engines 12 a, 12 b. Relatively smaller gears for the same output load may be provided in the FIG. 8 arrangement as each module carries half the load of each module in FIG. 6.

Referring to FIG. 9, a system similar to the FIG. 6 system provides coaxial counter rotating system 10″ with three engines 12 a, 12 b, and 12 c. An upper set of modules 16 u drives an upper output gear 50 u and shaft 14 u while a lower set of modules 161 drives a lower output gear 501 and shaft 141. Shaft 141 is mounted within shaft 14 u such that a coaxial counter rotating rotor system is provided.

The number of the Split Modules in the gearbox depends on aircraft configuration, number of engines and transmitted power. These modules are located around last stage output gear that combines power from each one and transmits it to the main rotor. The floating pinion, which is a part of the second stage of reduction, provides equal load balance between all gears engaged in the power train.

It should be understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude of the vehicle and should not be considered otherwise limiting.

The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention. 

1. A split torque gearbox system comprising: a first spur gear mounted for rotation about a first spur gear axis of rotation; a second spur gear mounted for rotation about a second spur gear axis of rotation; and a floating pinion gear mounted to a radially unsupported pinion shaft in a cantilever manner and driven by said radially unsupported pinion shaft, said floating pinion gear mounted for rotation about a floating pinion axis of rotation which provides a resilient characteristic, said floating pinion gear meshed with said first spur gear and said second spur gear, said floating pinion gear axis of rotation displaceable to split a load between said first spur gear and said second spur gear, said floating pinion axis of rotation, said first spur gear axis of rotation, and said second spur gear axis of rotation located along a common line, said radially unsupported pinion shaft driven through a gear mesh generally transverse to the floating pinion axis of rotation such that said radially unsupported pinion shaft is displaceable off said common line to define a displacement envelope within which said floating pinion gear axis of rotation may he displaced through flexing of said radially unsupported pinion shaft to split said load between said first spur gear and said second spur gear.
 2. The split torque gearbox system as recited in claim 1, further comprising a face gear mounted to said pinion shaft to define said gear mesh generally transverse to the floating pinion axis of rotation.
 3. The split torque gearbox system as recited in claim 2, wherein said gear mesh includes a spiral bevel gear teeth arrangement.
 4. The split torque gearbox system as recited in claim 1, further comprising: a first double helical gear driven by said first spur gear, said first double helical gear defined along said first spur gear axis of rotation; and a second double helical gear driven by said second spur gear, said second double helical gear defined along said second spur gear axis of rotation.
 5. The split torque gearbox system as recited in claim 4, further comprising an output gear meshed with said first and second double helical gear.
 6. The split torque gearbox system as recited in claim 5, further comprising a main rotor shaft driven by said output gear.
 7. The split torque gearbox system as recited in claim 1, wherein said floating pinion gear is mounted to a distal end of said radially unsupported pinion shaft.
 8. The split torque gearbox system as recited in claim 1, wherein a displacement envelope within which said floating pinion gear axis of rotation may be displaced is non-linear.
 9. The split torque gearbox system as recited in claim 1, wherein said displacement envelope is transverse to said floating pinion gear axis of rotation.
 10. The split torque gearbox system as recited in claim 1, wherein said displacement envelope is generally diamond shape.
 11. The split torque gearbox as recited in claim 1, wherein said floating pinion axis of rotation, said first spur gear axis of rotation, and said second spur gear axis of rotation are generally parallel.
 12. The split torque gearbox system as recited in claim 5, wherein said first double helical gear is of a smaller diameter than said first spur gear and second double helical gear is of a smaller diameter than said second spur gear.
 13. The split torque gearbox system as recited in claim 1, further comprising: a face gear driven about a face gear axis of rotation, said radially unsupported pinion shaft mounted to said face gear; a first gear driven by said first spur gear, said first gear defined along said first spur gear axis of rotation; a second gear driven by said second spur gear, said second gear defined along said second spur gear axis of rotation; an output gear meshed with said first gear and second gear; and a first spur gear periphery of said first spur gear and a second spur gear periphery of said second spur gear at least partially overlaps an output gear periphery of said output gear adjacent a first side of said output gear, and a face gear periphery of said face gear at least partially overlaps said output gear periphery adjacent a second side of said output gear.
 14. The split torque gearbox system as recited in claim 13, further comprising: an input shaft meshingly engaged with said face gear to define a gear mesh generally transverse to the floating pinion axis of rotation, said input shaft non-perpendicular to the floating pinion axis of rotation.
 15. The split torque gearbox system as recited in claim 13,wherein said first gear includes a first double helical gear and said second gear includes a second double helical gear.
 16. The split torque gearbox system as recited in claim 13, further comprising a main rotor shaft driven by said output gear.
 17. A split torque gearbox system for a rotary wing aircraft comprising: an input shaft; a face gear driven by said input shaft about a face gear axis of rotation; a first spur gear mounted for rotation about a first spur gear axis of rotation; a second spur gear mounted for rotation about a second spur gear axis of rotation; and a floating pinion gear mounted to a radially unsupported pinion shaft in a cantilever manner and driven by said radially unsupported pinion shaft mounted to said face gear, said floating pinion gear mounted for rotation about a floating pinion axis of rotation which provides a resilient characteristic said floating pinion gear meshed with said first spur gear and said second spur gear, said floating pinion axis of rotation, said first spur gear axis of rotation, and said second spur gear axis of rotation located along a common line, said floating pinion axis of rotation displaceable off said common line to define a displacement envelope within which said floating pinion gear axis of rotation may be displaced through flexing of said radially unsupported pinion shaft to split a load between said first spur gear and said second spur gear; a first double helical gear driven by said first spur gear, said first double helical gear defined along said first spur gear axis of rotation; a second double helical gear driven by said second spur gear, said second double helical gear defined along said second spur gear axis of rotation; and an output gear meshed with said first and second double helical gears.
 18. The split torque gearbox system as recited in claim 17, further comprising a main rotor shaft driven by said output gear.
 19. The split torque gearbox system as recited in claim 17, wherein said input shaft is driven by a gas turbine engine.
 20. The split torque gearbox system as recited in claim 17, wherein said face gear defines a gear face perpendicular to said face gear axis of rotation, said input shaft angled relative said gear face.
 21. The split torque gearbox system as recited in claim 18, wherein said floating pinion axis of rotation, said first spur gear axis of rotation, and said second spur gear axis of rotation are generally parallel to a main rotor axis of rotation defined by said main rotor shaft.
 22. The split torque gearbox system as recited in claim 17, wherein a first spur gear periphery of said first spur gear and a second spur gear periphery of said second spur gear at least partially overlaps an output gear periphery of said output gear adjacent a first side of said output gear, and a face gear periphery of said face gear at least partially overlaps said output gear periphery adjacent a second side of said output gear.
 23. A method of splitting torque within a split torque gearbox system comprising the steps of: (1) mounting a floating pinion gear to a radially unsupported pinion shaft in a cantilever manner and driving said floating pinion gear about a pinion gear axis of rotation through said radially unsupported pinion shaft which provides a resilient characteristic, the radially unsupported pinion shaft driven through a gear mesh generally transverse to the pinion gear axis; and (2) engaging the floating pinion with a first gear and a second gear, the first gear rotating around a first gear axis of rotation, the second gear rotating around a second gear axis of rotation, the first gear axis of rotation, the second gear axis of rotation and the pinion gear axis of rotation located along a common line, the pinion gear axis of rotation displaceable off the common line to define a displacement envelope within which the floating pinion gear axis of rotation may be displaced through flexing of the radially unsupported pinion shaft to split a load between the first gear and the second gear.
 24. A method as recited in claim 23, further comprising the steps of: driving a first double helical gear by the first gear, the, first double helical gear rotating about the first gear axis of rotation and axially movable along the first gear axis of rotation; and driving a second double helical gear by the second gear, the second double helical gear rotating about the second gear axis of rotation, and axially movable along the second gear axis of rotation.
 25. A method as recited in claim 24, further comprising the steps of: driving an output gear about an output gear axis of rotation with the first and second double helical gear.
 26. A method as recited in claim 24, further comprising the steps of: driving a rotor system about the output gear axis of rotation with the output gear.
 27. A method as recited in claim 23, further comprising the steps of: driving a face gear which defines the gear mesh generally transverse to the pinion gear axis about a face gear axis of rotation with a high speed input shaft; driving the floating pinion with the face gear through a floating pinion shaft.
 28. A method as recited in claim 27, further comprising the steps of: driving the high speed input shaft along an input shaft axis of rotation which is angled relative the face gear.
 29. A method as recited in claim 27, further comprising the steps of: driving a second face gear about a second face gear axis of rotation, the second face gear axis of rotation parallel to the face gear axis of rotation.
 30. A method as recited in claim 27, further comprising the steps of: driving a second face gear about a second face gear axis of rotation, the second face gear axis of rotation defined along the face gear axis of rotation. 